100 years as key manufacturers
Technical features of keys
In this article, we are going to explain what keys are, how they are made, common applications for keys, and the benefits they offer. Whether you're an engineer, technician or just curious to find out more about how these small parts work, you're in the right place! Let us introduce you to the fascinating world of keys.
- What are keys?
- How are keys made?
- Example applications for keys
- Advantages of using keys
What do keys do?
Keys are essential components for the transmission of motion in many industrial applications. They are used to rotate two parts, such as a shaft and a pulley or gear, allowing force and movement to be transmitted. There are different types of keys, such as keys with rounded ends (type A), straight ends (type B), keys with one round end and one straight end (type C or type AB), as well as gib head keys (DIN 6887) and Woodruff keys (DIN 6888 / NFE 22179).
Manufacturing keys
The process of manufacturing keys can vary depending on the needs and specifications of each application.
Most keys are made out of resistant materials such as carbon steel or stainless steel, but also non-ferrous metals such as brass, bronze, etc.
The material grade and sizing of the key depend on the application requirements, especially the size of the shaft and pulley, as well as the forces to be transmitted and the application environment.
At Gardette Industrie, we manufacture our keys with materials such as medium-hard steels, heat treatment steels, stainless steels, exotic materials (high-alloy steels, complex stainless steels, Hastelloy/Monel/Inconel nickel alloys...) or any other material suited to the client's needs.
The first step in producing keys is choosing a material. This choice will depend on the client's desired application and requirements.
Our unique 100% internal manufacturing process
At Gardette, we are the only manufacturer in the world to have our own cold rolling, cold drawing and heat treatment plant. This equipment allows us to manufacture a wide variety of standard and special profiles in various materials such as steel, stainless steel, aluminium, as well as copper and nickel alloys.
Once a material has been chosen, we cut it to the desired length and keys are machined using special machines equipped with cutting tools such as saws or milling machines. At Gardette, this stage takes place in our dedicated cutting section.
- Type B keys (straight-ended) are made using cutting or sawing machines. *
- As for type A keys and any other keys with complex shapes at their end, the length and two rounded ends are achieved via a machining operation with special shaped tools, using unique technologies specially developed by us.
At Gardette, we offer a wide range of finishing operations which can be adapted to the specific expectations and needs of each customer. Our fleet of machines includes numerical control machining centres, robot systems, as well as grinding machines (both flat and double disc) to guarantee ultra-precise tolerances or a certain specified roughness. In addition, we have a long calibration island that allows us to perform operations such as material cubing, creating shoulders or slopes on the parts.
Finally, we have also integrated a fleet of state-of-the-art vibratory finishing machines for deburring and to ensure products of the utmost quality.
The importance of vibratory finishing when manufacturing keys
Vibratory finishing is an important step in the manufacturing process for improving the quality and finish of parts. It can be used to remove burrs, improve surface roughness, and curves / radiates sharp edges, which can improve their appearance and help them function better.
At Gardette, we use two technologies for vibratory finishing:
- Vibrating bowls
- Centrifuging with rotating bottom.
The choice between vibrating bowels or centrifugation with a rotating bottom depends on the specificities of the parts to be treated, the client's desired finish and the requirements of the manufacturing process.
Our surface treatments for keys
Once the key has been manufactured, it may undergo a surface or heat treatment to improve its appearance and/or its corrosion or wear resistance.
At Gardette, we offer a wide range of surface and heat treatments to suit our clients' specific requirements. The most common surface treatments are zinc plating, burnishing, phosphatising, and painting. As for heat treatments, we can perform quenching, tempering and annealing.
We understand that each client has their own heat and surface treatment needs, depending on their applications and requirements. We are committed to providing tailor-made solutions to meet these needs, using cutting-edge techniques and ensuring optimal treatment quality to ensure customer satisfaction.
What about quality control?
The final stage in our process here at Gardette is to perform a thorough check on the key. We carry out meticulous quality checks both during production and once manufacturing operations have finished, ensuring that the key meets the highest quality standards.
Our expert technicians use state-of-the-art, high-precision measurement tools to check dimensions, tolerances, and other critical specifications. We aim to ensure that every key that leaves our workshop meets customer requirements. Quality is a priority at Gardette and we are committed to providing high-quality parts to our customers.
Example applications for keys
Keys are often used to transmit rotational force from a shaft to a rotating part, such as a pulley, a gear, or a gear wheel.
Keys are used in various industrial machines such as motors, machine tools, manufacturing equipment, etc.
Keys can also be used for specific applications, such as power transmission systems for conveyors, lifting equipment, transport equipment, agricultural machinery, etc.
At Gardette, we work with the automotive, civil & military aeronautics, textile and nuclear sectors, as well as with manufacturers of moulds, motors and pumps.
Advantages of using keys
Keys offer numerous advantages compared to other mechanical fastening means such as cable ties or welding. These include:
- High torque transmission: Keys are designed to transmit high torques in mechanical assemblies. For example, a 25mm-wide key can transmit a torque of over 700 Nm, making it a suitable option for applications that require high torque transmission.
- Rigidity & stability: Keys offer a rigid and stable connection between the assembled elements, which can be important in applications requiring high precision and dimensional stability.
- Long-lasting: Keys are typically made out of steel or stainless steel, making them resistant to corrosion, wear & tear, and other types of damage. This can help extend assembly life.
- Ease of installation: Keys are relatively easy to install and replace in an assembly, with simple and well-established assembly procedures.
- Widely available: Keys are widely used and available in numerous sizes, shapes, and configurations, making them a common and easily accessible option on the market.
- Standardised design: The keys are manufactured according to standardized design and manufacturing standards, making it easy to integrate them into existing assemblies or into new designs.
In short, keys are essential components in mechanical systems in order to ensure efficient and secure power transmission. Appropriate use, regular monitoring, and adequate maintenance are essential to make sure they function properly and to prevent potential failures.
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